CN113502472B - Cladding equipment and cladding method for continuous isothermal gradient cladding of steel rail surface - Google Patents

Cladding equipment and cladding method for continuous isothermal gradient cladding of steel rail surface Download PDF

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CN113502472B
CN113502472B CN202110779154.5A CN202110779154A CN113502472B CN 113502472 B CN113502472 B CN 113502472B CN 202110779154 A CN202110779154 A CN 202110779154A CN 113502472 B CN113502472 B CN 113502472B
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cladding
steel rail
copper wheel
electrode group
wheel electrode
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CN113502472A (en
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戴挺
王惟钊
顾德宇
邱钰雯
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Southeast University
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    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C24/00—Coating starting from inorganic powder
    • C23C24/08—Coating starting from inorganic powder by application of heat or pressure and heat
    • C23C24/10—Coating starting from inorganic powder by application of heat or pressure and heat with intermediate formation of a liquid phase in the layer
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C24/00—Coating starting from inorganic powder
    • C23C24/08—Coating starting from inorganic powder by application of heat or pressure and heat
    • C23C24/10—Coating starting from inorganic powder by application of heat or pressure and heat with intermediate formation of a liquid phase in the layer
    • C23C24/103—Coating with metallic material, i.e. metals or metal alloys, optionally comprising hard particles, e.g. oxides, carbides or nitrides
    • E—FIXED CONSTRUCTIONS
    • E01—CONSTRUCTION OF ROADS, RAILWAYS, OR BRIDGES
    • E01B—PERMANENT WAY; PERMANENT-WAY TOOLS; MACHINES FOR MAKING RAILWAYS OF ALL KINDS
    • E01B31/00—Working rails, sleepers, baseplates, or the like, in or on the line; Machines, tools, or auxiliary devices specially designed therefor
    • E01B31/02—Working rail or other metal track components on the spot
    • E01B31/18—Reconditioning or repairing worn or damaged parts on the spot, e.g. applying inlays, building-up rails by welding; Heating or cooling of parts on the spot, e.g. for reducing joint gaps, for hardening rails

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
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  • Organic Chemistry (AREA)
  • Architecture (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Heat Treatment Of Articles (AREA)

Abstract

The invention discloses a cladding device for continuous equal-temperature-gradient cladding of a steel rail surface, which comprises a heating system and a cladding system, wherein the cladding system is used for carrying out continuous cladding on the steel rail surface, the heating system comprises a preheating copper wheel electrode group and a heat-preservation copper wheel electrode group, the preheating copper wheel electrode group and the heat-preservation copper wheel electrode group are both in contact with the steel rail surface and the side surface to heat the steel rail surface, the cladding point of the cladding system is positioned between the preheating copper wheel electrode group and the heat-preservation copper wheel electrode group, and the cladding point is closer to the preheating copper wheel electrode group. The preheating copper wheel electrode group is adopted to preheat the steel rail before cladding, and the heat preservation copper wheel electrode group is adopted to preserve heat of the steel rail after cladding, so that metal is continuously cladded in a cladding area under equal temperature gradient, the problems of large internal stress, easy cracking and the like of a cladding layer caused by chilling during melting and solidification of metal in a common cladding process are avoided, a continuous and stable high-quality cladding layer is obtained, and the problem of poor bonding between the cladding layer and the steel rail is solved.

Description

Cladding equipment and cladding method for continuous isothermal gradient cladding of steel rail surface
Technical Field
The invention relates to steel rail surface treatment, in particular to cladding equipment and a cladding method for continuous equal-temperature gradient cladding of a steel rail surface.
Background
With the development of society, the importance of traffic is more and more prominent, and in strong traffic countries, railways are first, and rail transportation is one of important traffic ways. The rail of the bearing train is more seriously damaged due to high-speed rail running. In the face of rail damage, two main solutions are currently available, one is to improve the surface performance of the rail by alloying and other means before service, and the other is to replace the damaged rail and then transport the rail to a factory for repair or repair the rail on site. Both of these methods, while effective, still have drawbacks. For surface strengthening before service, the performance improvement effect is limited, and damage can not be avoided along with the increase of the operation time. Because the steel rail is generally made of high manganese steel, U75V and other alloy steels with medium and high carbon content, the weldability is poor, the cladding repair process of the steel rail is complex, the repair is difficult, and the repair quality is low, so the time and the economic cost for repairing the damaged steel rail are too high.
Disclosure of Invention
The purpose of the invention is as follows: aiming at the defects, the invention provides cladding equipment for carrying out cladding repair on the damaged steel rail, which is used for carrying out continuous isothermal gradient cladding on the surface of the steel rail.
The invention also provides a cladding method of the cladding equipment.
The technical scheme is as follows: in order to solve the problems, the invention adopts cladding equipment for continuous equal-temperature-gradient cladding of the surface of the steel rail, which comprises a heating system and a cladding system, wherein the cladding system is used for carrying out continuous cladding on the surface of the steel rail, the heating system comprises a preheating copper wheel electrode group and a heat-preservation copper wheel electrode group, the preheating copper wheel electrode group and the heat-preservation copper wheel electrode group are both in contact with the surface and the side surface of the steel rail to heat the surface of the steel rail, the cladding point of the cladding system is positioned between the preheating copper wheel electrode group and the heat-preservation copper wheel electrode group, and the cladding point is closer to the preheating copper wheel electrode group.
Further, the distance L = T V is set between the preheating copper wheel set and the cladding point, wherein T is the heat preservation time after the steel rail is clad, and V is the feeding speed of the steel rail.
Further, the cladding system comprises a cladding device, a feeding device and a cooling device, the cladding device comprises a cladding head and a two-axis moving device, the two-axis moving device drives the cladding head to move along two directions which are vertical, horizontal and perpendicular to the feeding direction of the steel rail, the feeding device is used for providing cladding materials for the cladding head, and the cooling device is used for cooling the cladding head.
Further, the speed U of the cladding head moving along the horizontal direction meets the formula W m >VW/U, wherein W m The width of a melting channel formed on the surface of the steel rail by melting and cladding materials by a melting and cladding head is W, and W is the width of a melting and cladding layer on the surface of the steel rail.
Further, still include gas protection system, gas protection system includes air supply, air pump, atmosphere gas supply pipe, working gas supply pipe and atmosphere cabin, cladding device, preheating copper wheel electrode group and heat preservation copper wheel electrode group set up in the atmosphere cabin, the air supply passes through the atmosphere gas supply pipe and carries inert gas to the atmosphere cabin in, the air supply passes through the working gas supply pipe and carries inert gas to cladding the head, the air pump is taken out the gas in the atmosphere cabin.
The steel rail cladding device is characterized by further comprising an observation and detection system, wherein the observation and detection system comprises an infrared thermal imager, a video sensor and a melting track quality detection system, the infrared thermal imager is used for measuring the temperature distribution of the steel rail to be clad, the video sensor is used for collecting the machining appearance of the steel rail to be clad, and the melting track quality detection system is used for detecting the quality of a melting track formed on the surface of the steel rail by cladding materials of a cladding head.
The control system controls the preheating copper wheel electrode group and the heat preservation copper wheel electrode group to work so as to control the temperature of the steel rail, controls the movement of the cladding head, and processes and displays detection data of the observation detection system.
The invention also discloses a cladding method of the cladding equipment, which comprises the following steps:
s1, feeding a steel rail, positioning a cladding part, and providing protective gas for a cladding working environment;
s2, preheating the copper wheel electrode group and the heat preservation copper wheel electrode group simultaneously;
s3, cladding the steel rail after the steel rail reaches the preheating temperature, and insulating the cladded steel rail by using an insulating copper wheel electrode group;
and S4, positioning the next cladding position of the steel rail after cladding, and repeating the step S2 and the step S3.
The invention also discloses a cladding device for continuous equal-temperature-gradient cladding of the surface of the steel rail, which comprises two cladding units working synchronously, a connecting rod for connecting the two cladding units and a driving device, wherein each cladding unit comprises a heating system, a cladding system and an atmosphere cabin, the two ends of the connecting rod are respectively connected with the atmosphere cabins of the two cladding units, the driving device drives the atmosphere cabins of the two cladding units to synchronously run on the steel rail on the two sides of the rail, the cladding system is arranged in the atmosphere cabins and is used for carrying out continuous cladding on the surface of the steel rail, the heating system comprises a preheating copper wheel electrode group and a heat-preservation copper wheel electrode group, the preheating copper wheel electrode group and the heat-preservation copper wheel electrode group are both in contact with the rail surface and the side surface to heat the surface of the steel rail, the cladding point of the cladding system is positioned between the preheating copper wheel electrode group and the heat-preservation copper wheel electrode group, and the cladding point is closer to the heating copper wheel group.
The invention also discloses a cladding method of the cladding equipment, which comprises the following steps:
s1, arranging two atmosphere cabins on steel rails on two sides of a track respectively, positioning a cladding part, and filling protective gas into the atmosphere cabins;
s2, preheating the copper wheel electrode group and the heat preservation copper wheel electrode group simultaneously;
s3, cladding the steel rail after the steel rail reaches the preheating temperature, and insulating the clad steel rail by using an insulating copper wheel electrode group;
and S4, after cladding, simultaneously driving the two cladding units to move on the steel rail by the driving device, positioning the next cladding part of the steel rail, and repeating the step S2 and the step S3.
Has the advantages that: compared with the prior art, the invention has the obvious advantages that the preheating copper wheel electrode group is adopted to preheat the steel rail before cladding, and the heat preservation copper wheel electrode group is adopted to preserve heat of the steel rail after cladding, so that metal is continuously cladded in a cladding area under an equal temperature gradient, and the problems of large internal stress, easy cracking and the like of a cladding layer caused by chilling during melting and solidification of metal in a common cladding process are avoided, thereby obtaining a continuous and stable high-quality cladding layer and solving the problem of poor bonding between the cladding layer and the steel rail.
Drawings
Fig. 1 is a schematic view of a system of cladding apparatus of the present invention;
fig. 2 is a schematic structural view of the cladding apparatus of the present invention;
FIG. 3 (a) is a schematic view showing the arrangement between a preheating copper wheel electrode group or a heat-insulating copper wheel electrode group and a steel rail according to the present invention; FIG. 3 (b) is a schematic view showing the arrangement between the pre-heating copper wheel electrode group and the heat-insulating copper wheel electrode group and the steel rail according to the present invention;
FIG. 4 is a schematic view of cladding equipment in a single-track feeding mode according to the present invention;
fig. 5 is a schematic working diagram of cladding equipment in the track online mode according to the present invention;
FIG. 6 is a graph showing the average hardness of the substrate in relation to the average hardness of the cladding layer at different preheating temperatures;
FIG. 7 is a graph showing the relationship between the coefficient of friction of the substrate and the cladding layer at different preheating temperatures.
Detailed Description
Example one
As shown in fig. 1 and 2, the cladding equipment for continuous equal-temperature-gradient cladding of the surface of the steel rail of the invention comprises a cladding system 7, a heating system 1, a gas protection system 2, a control system 4 and an observation and detection system 5; the cladding system 7 comprises a cladding device, a feeding device 6 and a cooling device 3, the cladding device is arranged in the atmosphere cabin 8, the cladding device comprises a cladding head 71 and a two-axis moving device 72, the cladding head 71 is arranged on the two-axis moving device 72, the two-axis moving device 72 drives the cladding head 71 to move along two directions which are vertical (Z axis) and horizontal and perpendicular to the feeding direction (X axis) of the steel rail, the feeding direction of the steel rail is Y axis direction, and the X axis, the Y axis and the Z axis are three coordinate axes in a space rectangular coordinate system. The speed U (i.e. cladding speed) of the cladding head 71 moving along the X-axis direction satisfies the formula W m >VW/U, wherein W m In order to ensure that the cladding head 71 melts cladding materials to form the width of a cladding layer on the surface of the steel rail, W is the width of the cladding layer on the surface of the steel rail, V is the feeding speed of the steel rail, the cladding process is carried out in a reciprocating mode along the width direction of the steel rail, and the full coverage of a cladding area is formed by matching with synchronous steel rail feeding. The feeding device 6 is used for providing cladding materials for the cladding head 71, the cooling device 3 is used for cooling the cladding head 71, and the feeding device 6 comprises a paraxial wire feeding device 61 or a powder feeding device 62 for feeding powder to the cladding head 71, which feeding mode is specifically selected and determined according to the selected cladding materials and the specific process. The cooling device 3 comprises a water cooler 31, a water outlet pipe 311 and a water inlet pipe 312, wherein cold water in the water cooler 31 flows through the cladding head 71 through the water outlet pipe 311 and flows back to the water cooler 31 through the water inlet pipe 312, and the cladding head 71 is cooled by water cooling.
The gas protection system 2 comprises a gas source 21, a gas pump 22, an atmosphere gas feed pipe 24, a working gas feed pipe 23 and an atmosphere chamber 8, wherein the atmosphere chamber 8 is a foundation for installing all parts of equipment and has certain rigidity. The atmosphere cabin 8 is provided with a steel rail inlet and outlet, the steel rail is fed from the steel rail inlet and is delivered from the steel rail outlet after cladding, a flexible sealing piece is arranged between the steel rail inlet and outlet and the steel rail, the cladding process is completed in the atmosphere cabin 8, the gas source 21 conveys protective gas into the atmosphere cabin 8 through the atmosphere gas feed pipe 24, the protective gas is inert gas and provides a low-oxygen environment for the cladding process, the oxygen content of the inert gas in the atmosphere cabin 8 is lower than 5%, the gas source 21 conveys the inert gas to the cladding head 71 through the working gas feed pipe 23, and the air pump 22 pumps the air in the atmosphere cabin 8, so that the protective gas is filled, and the air pumping and the protective gas filling are carried out simultaneously. And a cladding protective gas atmosphere is created, and the problem of low quality of the steel rail cladding process is effectively solved.
The heating system 1 comprises an adjustable power supply 12 and a copper wheel electrode group 11, wherein the copper wheel electrode group 11 comprises a preheating copper wheel electrode group 111 and a heat preservation copper wheel electrode group 112, in the embodiment, the preheating copper wheel electrode group 111 and the heat preservation copper wheel electrode group 112 are made of high-strength high-conductivity copper and are respectively connected to two poles of the power supply, as shown in fig. 3 (a) (b), the preheating copper wheel electrode group 111 and the heat preservation copper wheel electrode group 112 are both in contact with the rail surface and the side surface of the steel rail 9 to heat the surface of the steel rail, a cladding point of the cladding system 7 is located between the preheating copper wheel electrode group 111 and the heat preservation copper wheel electrode group 112 and close to the heating copper wheel group, the preheating copper wheel electrode group 111 preheats the steel rail before cladding, and the heat preservation copper wheel electrode group 112 preserves heat of a cladding layer in a cladding process and after cladding. And the preheating copper wheel electrode group 111 is arranged close to the steel rail inlet in the atmosphere cabin 8, the cladding preheating temperature, the heat preservation temperature and the heat preservation time required after cladding are determined according to the characteristics of the steel rail size, the material and the cladding material, and the arrangement position of the heat preservation copper wheel electrode group 112 is obtained according to the steel rail feeding speed. And the setting distance L = T V between the preheating copper wheel set and the cladding point, wherein T is the heat preservation time after the steel rail is cladded.
In this embodiment, the power supply is transformed from three-phase alternating current to low-voltage alternating current by a high-power transformer, the primary coil of the transformer has 190 turns, and the coils are respectively led at 95 turns, 64 turns and 48 turns, so that the ratio of the secondary turns to the power supply transformer source is 190: 1. 95: 1. 64: 1. 48:1, so that four gears with heating voltages of 2V, 4V, 6V and 8V are selectable. The source level realizes the program control of the heating power by a silicon controlled rectifier alternating current power control mode, and the control mode is that the control system 4 outputs weak current control signals according to PID control logic to realize the power control of the conduction angle of the silicon controlled rectifier and realize the control of the preheating temperature and the heat preservation temperature of the steel rail. The heating system 1 and the cladding system 7 work cooperatively to keep the stable preheating temperature of the surface of the workpiece, so that a cladding metal layer is melted and solidified under a stable temperature gradient during continuous cladding of the steel rail, and is cooled at a certain heat preservation temperature after cladding, thereby obtaining a high-quality cladding effect.
The observation and detection system 5 realizes online observation and detection of the cladding process, including temperature detection of the cladding area, video monitoring of the cladding point, online detection of the channel defect and the like. The observation and detection system 5 comprises an infrared thermal imager 51, a video sensor 52 and a melting channel quality detection system 53, wherein the infrared thermal imager 51 measures the temperature distribution of a preheating area and a heat preservation area of the steel rail to be clad, the video sensor 52 collects the processing appearance of the steel rail to be clad, and the melting channel quality detection system 53 detects the quality of a melting channel formed on the surface of the steel rail by melting and cladding materials of a cladding head 71. The data of the observation and detection system 5 is transmitted to the control system 4 in real time for processing and result presentation.
The control system 4 comprises a computer 41 integrating various data interfaces, a weak current control board and a processor, and the computer control system 4 realizes the preheating and heat-preserving temperature control, cladding movement and process control, and the processing and display functions of detected data.
The cladding method for cladding the steel rail by the cladding equipment is a single-rail feeding mode, as shown in fig. 4, the single-rail feeding mechanism feeds the steel rail workpiece at a constant speed to realize cladding, and the method comprises the following specific steps:
s1, firstly, determining the length of a heat preservation section, and adjusting the position of a heat preservation copper wheel electrode group 112; before the surface of the steel rail is clad, firstly connecting two sets of copper wheel electrode groups 11 to two poles of a low-voltage large-current power supply, and forming direct resistance heating between the two sets of copper wheels so as to rapidly heat the surface of the steel rail to a preheating temperature;
s2, checking whether all parts of the equipment are normal or not;
s3, feeding the steel rail into the atmosphere cabin 8, positioning a cladding part, starting the gas protection system 2, filling protective gas into the atmosphere cabin 8, and providing a protective gas environment for a cladding working environment;
s4, after the oxygen content of the inert gas in the atmosphere cabin 8 is lower than 5%, starting the heating system 1, and simultaneously preheating the steel rail by the preheating copper wheel electrode group 111 and the heat preservation copper wheel electrode group 112;
s5, after the steel rail reaches the preheating temperature, starting a cladding system 7, cladding the steel rail by the cladding system 7, enabling a cladded metal layer to enter a heat preservation area along with the feeding movement of the steel rail, preserving the heat of the cladded steel rail for a period of time by a heat preservation copper wheel electrode group 112, and then naturally cooling to form a high-quality cladding layer;
and S6, positioning the next cladding part of the steel rail after cladding, and repeating the step S2 and the step S5.
Example two
The utility model provides a cladding equipment that rail surface equant temperature gradient melts and covers in succession, includes that two synchronous working melt and cover the unit, connect two connecting rods that melt and cover the unit, drive arrangement, every melts and covers the unit and set up the same with the cladding equipment in embodiment one, no longer gives details here, and two atmosphere cabins 8 that melt and cover the unit are connected respectively to the connecting rod both ends, and drive arrangement drives two atmosphere cabins 8 that melt and cover the unit and move on the rail of track both sides in step.
In this embodiment, the method for cladding the steel rail by the cladding device is an online mode of the rail, as shown in fig. 5, a mechanism capable of running on the rail is assembled by combining two cladding units, and cladding is realized by walking at a constant speed under the traction of a vehicle or a mechanism, and the method specifically includes the following steps:
s1, respectively arranging two atmosphere cabins 8 on steel rails 9 on two sides of a track, determining the length of a heat preservation section, and adjusting the position of a heat preservation copper wheel electrode group 112; before cladding is carried out on the surface of the steel rail, firstly, two sets of copper wheel electrode groups 11 are connected to two poles of a low-voltage large-current power supply, and direct resistance heating is formed between the two sets of copper wheels, so that the surface of the steel rail is rapidly heated to a preheating temperature;
s2, checking whether all parts of the equipment are normal or not;
s3, the atmosphere cabin 8 runs on the steel rail under the driving of the driving device, a cladding part is positioned, the gas protection system 2 is started, protective gas is filled in the atmosphere cabin 8, and a protective gas environment is provided for a cladding working environment;
s4, after the oxygen content of the inert gas in the atmosphere cabin 8 is lower than 5%, starting the heating system 1, and simultaneously preheating the steel rail by the preheating copper wheel electrode group 111 and the heat preservation copper wheel electrode group 112;
s5, after the steel rail reaches the preheating temperature, starting a cladding system 7, cladding the steel rail by the cladding system 7, enabling a cladded metal layer to move along with a cladding unit and enter a heat preservation area, preserving the heat of the cladded steel rail for a period of time by a heat preservation copper wheel electrode group 112, and then naturally cooling to form a high-quality cladding layer;
and S6, positioning the next cladding position of the steel rail after cladding, and repeating the step S2 and the step S5.
And in the cladding process, the working state is observed in real time through the observation and detection system 5 to obtain the processing temperature, and the processing temperature is fed back to the computer control system 4 for temperature control. The computer control system 4 controls the feeding speed of the steel rail to be matched with the cladding process determined by cladding power, speed and raw material feeding amount, so that continuous cladding is realized, and the problem of poor bonding between a cladding layer and the steel rail in the traditional cladding method due to poor weldability of the alloy steel with medium-high carbon content is solved by adopting the continuous equal-temperature gradient cladding process.
In practical application, the surface cladding strengthening can be carried out before the steel rail is in service, for example, a cladding layer containing a large amount of bainite and martensite microstructures is prepared by a cladding process, and the strength, the toughness, especially the wear resistance and the strength are greatly improved compared with the steel rail, so that the performance of the steel rail is improved, and the service life is prolonged; but also can repair the damaged steel rail, thereby greatly shortening the time cost for repairing the damaged steel rail and improving the economic benefit
The equipment for continuous equal-temperature-gradient cladding on the surface of the steel rail provided by the embodiment can prepare the cladding layer with excellent performance under reasonable parameters, and the wear resistance, the strength and the like are greatly improved compared with a matrix. Table 1 shows the phase fraction of the microstructure of the cladding layer at three different preheating temperatures, and Table 2 shows the dimensions of the phases.
TABLE 1
Figure RE-GDA0003197733640000061
TABLE 2
Figure RE-GDA0003197733640000062
As can be seen, a large amount of micron-sized bainite exists at the three temperatures, the content of the submicron-sized martensite is not low, and the strength and the hardness of the cladding layer are ensured. FIGS. 6 and 7 show the average hardness and friction coefficient of the substrate and the cladding layer at different preheating temperatures, respectively. Obviously, the microhardness of the cladding layer prepared at each temperature is higher than that of the substrate, and meanwhile, the friction coefficient is reduced to different degrees, which shows that the wear resistance of the cladding layer is better than that of the substrate.

Claims (10)

1. The cladding equipment for continuous equal-temperature-gradient cladding of the surface of the steel rail is characterized by comprising a heating system (1) and a cladding system (7), wherein the cladding system (7) is used for carrying out continuous cladding on the surface of the steel rail, the heating system (1) comprises a preheating copper wheel electrode group (111) and a heat-preservation copper wheel electrode group (112), the preheating copper wheel electrode group (111) and the heat-preservation copper wheel electrode group (112) are in contact with the surface and the side surface of the steel rail to heat the surface of the steel rail, the cladding point of the cladding system (7) is located between the preheating copper wheel electrode group (111) and the heat preservation copper wheel electrode group (112), and the cladding point is closer to the preheating copper wheel electrode group (111).
2. Cladding apparatus according to claim 1, wherein the set distance between the pre-heating copper wheel electrode set (111) and the cladding point is L = T x V, where T is the holding time after the rail is clad and V is the rail feeding speed.
3. Cladding apparatus according to claim 1, wherein the cladding system (7) comprises a cladding device, a feeding device (6) and a cooling device (3), the cladding device comprises a cladding head (71) and a two-axis moving device (72), the two-axis moving device (72) drives the cladding head (71) to move along two directions which are vertical and horizontal and perpendicular to the feeding direction of the steel rail, the feeding device (6) is used for supplying cladding material to the cladding head (71), and the cooling device (3) is used for cooling the cladding head (71).
4. Cladding apparatus according to claim 3, wherein the speed U of the cladding head (71) moving in horizontal direction satisfies the formula W m >VW/U, wherein W m The width of a melting channel formed on the surface of the steel rail by melting and cladding materials by a cladding head (71) is W, and W is the width of a cladding layer on the surface of the steel rail.
5. Cladding apparatus according to claim 3, further comprising a gas protection system (2), said gas protection system (2) comprises a gas source (21), a gas pump (22), an atmosphere gas feed pipe (24), a working gas feed pipe (23) and an atmosphere chamber (8), said cladding apparatus, pre-heating copper wheel electrode set (111) and insulating copper wheel electrode set (112) are arranged in the atmosphere chamber (8), said gas source (21) feeds inert gas into the atmosphere chamber (8) through the atmosphere gas feed pipe (24), the gas source (21) feeds inert gas into the cladding head (71) through the working gas feed pipe (23), said gas pump (22) pumps out gas in the atmosphere chamber (8).
6. Cladding equipment according to claim 5, further comprising an observation and detection system (5), wherein the observation and detection system (5) comprises an infrared thermal imaging camera (51), a video sensor (52) and a melting track quality detection system (53), the infrared thermal imaging camera (51) is used for measuring the temperature distribution of the steel rail to be clad, the video sensor (52) is used for collecting the processing appearance of the steel rail to be clad, the melting track quality detection system (53) is used for detecting the quality of the melting track formed on the surface of the steel rail by the cladding head (71) through melting and cladding materials, and the data of the observation and detection system (5) is transmitted to the control system (4) in real time for processing and result presentation.
7. Cladding apparatus according to claim 6, further comprising a control system (4), said control system (4) controlling the operation of the pre-heating copper wheel electrode set (111) and the heat-insulating copper wheel electrode set (112) to control the rail temperature, the control system (4) controlling the movement of the cladding head (71), and processing and displaying the detection data of the observation detection system (5).
8. A cladding method of the cladding equipment according to any one of claims 1 to 7, comprising the following steps:
s1, feeding a steel rail, positioning a cladding part, and providing protective gas for a cladding working environment;
s2, preheating a steel rail by a preheating copper wheel electrode group (111) and a heat-preservation copper wheel electrode group (112) simultaneously;
s3, cladding the steel rail after the steel rail reaches the preheating temperature, and insulating the clad steel rail by using an insulating copper wheel electrode group (112);
and S4, positioning the next cladding part of the steel rail after cladding, and repeating the step S2 and the step S3.
9. A cladding device for continuous isothermal gradient cladding of a steel rail surface is characterized by comprising two cladding units working synchronously, a connecting rod for connecting the two cladding units and a driving device, wherein each cladding unit comprises a heating system (1), a cladding system (7) and atmosphere cabins (8), the two ends of the connecting rod are respectively connected with the atmosphere cabins (8) of the two cladding units, the driving device drives the atmosphere cabins (8) of the two cladding units to synchronously run on the steel rail on the two sides of a track, the cladding system (7) is arranged in the atmosphere cabin (8), the cladding system (7) is used for continuously cladding the surface of the steel rail, the heating system (1) comprises a preheating copper wheel electrode group (111) and a heat preservation copper wheel electrode group (112), the preheating copper wheel electrode group (111) and the heat preservation copper wheel electrode group (112) are both in contact with the surface and the side face of the steel rail and used for heating the surface of the steel rail, a cladding point of the cladding system (7) is located between the preheating copper wheel electrode group (111) and the heat preservation copper wheel electrode group (112), and the cladding point is closer to the heating copper wheel group.
10. Cladding method of a cladding apparatus according to claim 9, comprising the steps of:
s1, respectively arranging two atmosphere cabins (8) on steel rails on two sides of a track, positioning a cladding part, and filling protective gas into the atmosphere cabins (8);
s2, preheating a steel rail by a preheating copper wheel electrode group (111) and a heat-preservation copper wheel electrode group (112) simultaneously;
s3, cladding the steel rail after the steel rail reaches the preheating temperature, and insulating the clad steel rail by using an insulating copper wheel electrode group (112);
and S4, after cladding, simultaneously driving the two cladding units to move on the steel rail by the driving device, positioning the next cladding part of the steel rail, and repeating the step S2 and the step S3.
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